Composite cushions

ABSTRACT

A composite cushion includes a first cushioning element and a second cushioning element. The second cushioning element is formed in a manner that engages a peripheral engagement are of the first cushioning element to interlock the second cushioning element onto the first cushioning element. The second cushioning element may surround an outer periphery of the first cushioning element. In addition, a portion of the second cushioning element may be superimposed over a central cushioning area of the first cushioning element. Superimposed portions of the first and second cushioning elements may have an unsecured relationship (i.e., they are not directly secured to each other).

CROSS-REFERENCE TO RELATED APPLICATION

A claim for the benefit of priority to the Feb. 15, 2017 filing date ofU.S. Provisional Patent Application No. 62/459,518, titled COMPOSITECUSHIONS (“the '518 Provisional Application”), is hereby made pursuantto 35 U.S.C. § 119(e). The entire disclosure of the '518 Application is,by this reference, incorporated herein.

TECHNICAL FIELD

This disclosure relates generally to composite cushions and, morespecifically, to cushions that include a first cushioning element thatdefines a plurality of columnar cushioning cells and a second cushioningelement that is positioned adjacent to and mechanically engagesengagement features of the first cushioning element.

DISCLOSURE

In various aspects, this disclosure relates to composite cushions,including, but not limited to, the composite cushions themselves, aswell as to methods for fabricating composite cushions and methods forusing composite cushions.

A composite cushion according to this disclosure includes a firstcushioning element and a second cushioning element. The first cushioningelement includes a central cushioning area and a peripheral engagementarea, which is located outside of and adjacent to at least a portion ofthe outer periphery of the first cushioning element.

The first cushioning element, which is defined from a first cushioningmaterial, may include walls that define an outer periphery of the firstcushioning structure, as well as columnar cushioning cells. The columnarcushioning cells may be arranged in an array. The first cushioningmaterial, as well as the thicknesses of the walls, may enable thecolumnar cushioning cells to buckle. A first surface of the centralcushioning area may be defined by first ends of the walls and coincidewith first ends of the columnar cushioning cells. A second surface ofthe central cushioning area, which is opposite from the first surface,may be defined by second ends of the walls and coincide with second endsof the columnar cushioning cells, which second ends are opposite fromthe first ends of the columnar cushioning cells. A distance (ordistances) between the first surface and the second surface of thecentral cushioning area define a thickness (or thicknesses, or anaverage thickness) of the first cushioning element. The thickness of thecentral cushioning area may be referred to as a “cushioning thickness”of the first cushioning element.

Without limiting the scope of this disclosure, the central cushioningarea of the first cushioning element may be configured and/or made inthe same manners as the cushions described by any of U.S. Pat. Nos.5,749,111, 6,026,527, 6,413,458, 7,666,341, 8,424,137, 8,434,748,8,628,067, 8,919,750, and 8,932,692, the entire disclosures of which arehereby incorporated herein.

The peripheral engagement area of the first cushioning element may beformed integrally with the central cushioning area of the firstcushioning element and, thus, from the same material as that used toform the central cushioning area (e.g., the first cushioning material,etc.). The peripheral engagement area may be located outside of andadjacent to at least a portion of an outer periphery of the centralcushioning area. In some embodiments, the peripheral engagement area mayinclude engagement features that are spaced apart from one another atvarious locations outside of the central cushioning area. In otherembodiments, the peripheral engagement area may surround at least aportion of central cushioning area; e.g., it may comprise at least onecontinuous structure that is positioned adjacent to at least portions oftwo or more sides of the central cushioning area (e.g., at leastportions of two sides, one side and at least portions of two connectingsides, two sides and at least portions of two connecting sides, etc.).In still other embodiments, the peripheral engagement area maycompletely surround the central cushioning area.

The engagement features of the peripheral engagement area of the firstcushioning element may comprise any feature that can be mechanicallyengaged by corresponding, even complementary, features of the secondcushioning element. The engagement features may comprise engagementcells, which may be defined by one or more walls. Engagement cells maycomprise full cells, the entire peripheries of which are defined by oneor more walls that may be longitudinally when the first cushioningelement is oriented horizontally, or partial cells, in which one or moreof the walls that define the engagement cell that lacks at least aportion of at least one wall (e.g., includes an opening (e.g., a gapalong the height of the engagement cell, etc.)) or that is capable ofbeing opened (e.g., comprise a gap or a cut that defines a flap, etc.).The walls of the cells, whether full or partial, may be solid (i.e.,they may lack openings, or “windows”) or they may include openings. Thefirst cushioning material of the peripheral engagement area may defineflanges and other structures that may be configured to be securelyengaged by corresponding, even complementary, features of the secondcushioning element. In any event, portions of the second cushioningelement that engage the peripheral engagement area of the firstcushioning element may overlie (i.e., cover an upper surface of) theperipheral engagement area, underlie (i.e., cover a lower surface of)the peripheral engagement area, or overlie and underlie (i.e., coverupper and lower surfaces of) the peripheral engagement area.

A thickness (or thicknesses or an average thickness) of the peripheralengagement area, which may be referred to as an “engagement thickness”of the first cushioning element, may be defined by a distance (ordistances) between a first surface of the peripheral engagement area andan opposite, second surface of the peripheral engagement area. The firstand second surfaces of the peripheral engagement area may correspond to(e.g., face in the same general directions as, be continuous with, etc.)the first and second surfaces of the cushioning area.

In some embodiments, including those where the second cushioning elementis thicker than the first cushioning element or increases a thickness ofthe composite cushion, the engagement thickness of the peripheralengagement area of the first cushioning element may be less than,substantially the same as, or the same as the cushioning thickness ofthe central cushioning area of the first cushioning element. Inembodiments where the second cushioning element has a thickness that isthe same as or about the same as the thickness of the first cushioningelement or the thickness of the second cushioning element will notcontribute to the thickness of the composite cushion or will notsignificantly increase the thickness of the composite cushion, theengagement thickness may be less than the cushioning thickness.

The first cushioning material of the first cushioning element maycomprise any suitable cushioning material. Without limitation, the firstcushioning material may comprise a suitable elastic, resilient materialor a suitable viscoelastic material. The first cushioning material maydefine walls that are solid, open-celled, close-celled (e.g., cells thatare defined only by the first cushioning material; cells that aredefined by microspheres, microcapsules, etc.; etc.), or walls that haveother configurations. Some nonlimiting examples of gel materials thatmay be used as the first cushioning material are disclosed by U.S. Pat.Nos. 5,994,450 and 7,964,664, the entire disclosures of which are herebyincorporated herein. These types of materials are relatively heavy.

The second cushioning element of a composite cushion according to thisdisclosure, which is positioned adjacent to the first cushioning elementand may partially or completely laterally surround the first cushioningelement, may mechanically engage engagement features of the firstcushioning element. In this regard, the second cushioning element may beformed complementarily to, and even formed on, the peripheral cushioningarea of the first cushioning element. In specific embodiments, a secondcushioning material of the second cushioning element may extend into andeven through engagement cells of the peripheral engagement area of thefirst cushioning element, interlocking the second cushioning element andthe first cushioning element.

The second cushioning material of the second cushioning element of acomposite cushion according to this disclosure may be the same as thefirst cushioning material of the first cushioning element or differentfrom the first cushioning material of the first cushioning element. Insome embodiments, the second cushioning material may comprise alightweight cushioning material. The use of materials that arerelatively light in conjunction with a relatively heavy first cushioningelement to form a composite cushion may provide for a relativelylightweight cushion when compared with the weight of a cushion that ismade primarily from or completely from the relatively heavy firstcushioning material, while providing for a composite cushion thatprovides the benefits of a cushion made from the first cushioningmaterial and having the configuration of the first cushioning element.The second cushioning material may also provide the composite cushionwith a desired shape, which the first cushioning material may or may notbe able to provide. A wide variety of materials may be used to form thesecond cushioning element of a composite cushion according to thisdisclosure.

In some embodiments, the second cushioning element of a compositecushion may be located adjacent to or at least partially surround thefirst cushioning element of the composite cushion, with both majorsurfaces (i.e., the first and second surfaces) of the first cushioningelement remaining exposed. In some of those embodiments, where thesecond cushioning element completely surrounds an outer periphery of thefirst cushioning element, the second cushioning element may serve as a“racetrack” around the first cushioning element.

In embodiments where one or both major surfaces of the first cushioningelement remain exposed, edges of corresponding surfaces of the first andsecond cushioning elements may be flush or substantially flush,imparting the composite cushion with a continuous surface. Such acontinuous surface may be flat, or it may have a contour.

In other embodiments, a composite cushion may include a secondcushioning element that extends over at least a portion, or even anentirety of, at least one major surface of a central cushioning area ofa first cushioning element. In such an embodiment, a relief layer may bepositioned between superimposed portions of the central cushioning areaof the first cushioning element and the second cushioning element. Therelief layer may comprise any suitable flexible sheet, such as a cloth(e.g., a non-stretch cloth, a two-way stretchable cloth, a four-waystretchable cloth, etc.), a sheet of another material (e.g., polymer,quasi-woven polymer, woven polymer, etc.), etc. The relief layer may bepositioned against, but not adhered or otherwise secured to the surfaceof the central cushioning area of the first cushioning element, whichmay enable the superimposed portions of the central cushioning area andthe second cushioning element to move somewhat independently of oneanother. Such an arrangement may enable each of the first cushioningelement and the second cushioning element to function in a desiredmanner (e.g., substantially constant cushioning and resistance acrossthe second cushioning element; buckling of the first cushioning elementunder focused forces, while providing support to distributed forces;etc.) without significant interference from one another (e.g., theability of the first cushioning element to buckle at locations whereforces are focused will not be significantly diminished by a scrim thathas been adhered or otherwise secured to the first cushioning element toprevent the second cushioning material from entering into the columnarcushioning cells of the first cushioning element when the secondcushioning element is formed or secured to the first cushioning element,etc.).

Alternatively, portions of a second cushioning element that overlie allor part of the central cushioning area of a first cushioning element maydirectly contact the central cushioning area of the first cushioningelement. For example, ends (e.g., top ends, etc.) of at least some cellsof the central cushioning area of the first cushioning element may be atleast partially closed (e.g., by a membrane, etc.). In a specificembodiment, some of the cells of the central cushioning area may becompletely closed, while other cells may be partially closed (e.g., withopenings through a membrane, etc.) to impart the central cushioning areawith breathability through its thickness. The closed ends of such acentral cushioning area may provide a surface that is capable ofsupporting portions of the second cushioning element that are disposedthereover.

The first and second cushioning elements of a composite cushionaccording to this disclosure may provide the essential elements of acushion, or they may serve as a base for an even larger compositecushion. In a specific embodiment, a cushion comprising a bladder filledwith a deformable material that includes acrylic microspheres dispersedthroughout or held together by a viscous material may be positioned overa base that comprises a composite cushion with first and secondcushioning elements, as disclosed herein.

In another aspect, methods for fabricating, or making, compositecushions are disclosed. Such a method includes forming a firstcushioning element from a first cushioning material. The firstcushioning element is formed to include walls. The walls define columnarcushioning cells in a central cushioning area and engagement features ina peripheral engagement area, with the peripheral engagement area beinglocated adjacent to at least a portion of an outer periphery of thecentral cushioning area. The engagement features may include engagementcells, flanges, or other structures that protrude from the outerperiphery of the central cushioning area.

A second cushioning element of the composite cushion is formed with asecond cushioning material. As the second cushioning element is formed,portions of the second cushioning element may be defined that includeshapes that complement the shapes of the engagement features of theperipheral engagement area of the first cushioning element. Inembodiments where the engagement features comprise engagement cells, thesecond cushioning material may be introduced into and through theengagement cells to lock the second cushioning element onto the firstcushioning element. In embodiments where the engagement featurescomprise flanges or other structures, the second cushioning element mayform around and extend into recesses of the flanges, locking the secondcushioning element onto the flanges.

The first cushioning element may be formed by a variety of suitableprocesses, including by the use of molds (e.g., by injecting the firstcushioning material (e.g., a gel, etc.) into a mold, etc.). Once a firstcushioning element has been formed, it may be placed into another mold.In some embodiments, a relief layer may be applied to at least a portionof the first cushioning element. The relief layer may be placed on thefirst cushioning element without adhering to or otherwise being securedto the first cushioning element. With the first cushioning element andany relief layer(s) in the mold, the second cushioning material (e.g., arise in place foam, etc.) may be introduced into (e.g., injected, etc.)the mold to form the second cushioning element, including any engagementfeatures thereof, laterally adjacent to at least a portion of the firstcushioning element. In embodiments where the second cushioning materialis applied directly to the central cushioning area of the firstcushioning element and the second cushioning material enters into cellsof the central cushioning area, the second cushioning material may beremoved from those cells after the second cushioning element has beenformed.

Other aspects, as well as features and advantages of various aspects ofthe disclosed subject matter will become apparent to those of ordinaryskill in the art through consideration of the ensuing description, theaccompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a cross-sectional representation of an embodiment of acomposite cushion according to this disclosure, showing embodiments of afirst cushioning element that of the composite cushion and a secondcushioning element that at least partially surrounds a periphery of thefirst cushioning element and that at least partially covers a topsurface of the first cushioning element;

FIG. 2 is a partial perspective view of the first cushioning element ofthe composition cushion shown in FIG. 1, in which a peripheralengagement area of the first cushioning element has a steppedconfiguration relative to an outer periphery of a central cushioningarea of the first cushioning element;

FIG. 3 is a cross-sectional representation of another embodiment ofcomposite cushion that includes the first cushioning element of FIG. 1,with a second cushioning element that at least partially surrounds aperiphery of the first cushioning element;

FIG. 4 is a top view of the composite cushion of FIG. 3;

FIG. 5 is a partial perspective view of another embodiment of firstcushioning element, in which a peripheral engagement area of the firstcushioning element tapers downward from an outer periphery of a centralcushioning area of the first cushioning element;

FIG. 6 is a cross-sectional representation of the embodiment of thefirst cushioning element shown in FIG. 5;

FIG. 7 is a cross-sectional representation of yet another embodiment ofcomposite cushion, including yet another embodiment of first cushioningelement, in which a peripheral engagement area of the first cushioningelement comprises flanges that protrude from an outer periphery of acentral cushioning area of the first cushioning element;

FIG. 8 is a cross-sectional representation of a cushioning system thatincludes still another embodiment of a composite cushion according tothis disclosure, as well as a third cushioning element that has beenassembled with the composite cushion;

FIG. 9 is a partial perspective view of another embodiment of firstcushioning element, in which ends of cells of a central cushioning areaare at least partially closed; and

FIG. 10 is a cross-sectional representation of an embodiment ofcomposite cushion that includes an embodiment of first cushioningelement that includes a central cushioning area with cells that haveends that are at least partially closed.

DETAILED DESCRIPTION

With reference to FIG. 1, an embodiment of a composite cushion 1according to this disclosure is depicted. The composite cushion 1includes a first cushioning element 10 and a second cushioning element20.

As FIG. 1 and FIG. 2 depict, the first cushioning element 10 includes acentral cushioning area 12 and a peripheral engagement area 17. Thecentral cushioning area 12 includes a top surface 12 t and a bottomsurface 12 b. A plurality of cells 13 may extend substantially throughthe central cushioning area, between the top surface 12 t and the bottomsurface 12 b. The cells 13, which may be arranged in an array, aredefined by side walls 14, which may be formed from a compressible,resilient material. Together, the configurations of the cells 13 and theside walls 14 that define the cells 13, the arrangement of the cells 13,and the material from which the side walls 14 are formed may provide aplurality of so-called “buckling columns” in the central cushioning area12. In some embodiments, the side walls 14 that define a cell 13 maybuckle independently from the side walls 14 that define non-adjacent, ordistant, cells 13.

The peripheral engagement area 16 is located adjacent to, and protrudesfrom, at least a portion of an outer periphery 15 of the centralcushioning area 12. In some embodiments, the peripheral engagement area16 may surround a portion of the central cushioning area 12. In otherembodiments, the peripheral engagement area 16 may completely surroundthe central cushioning area 12.

Like the central cushioning area 12, the peripheral engagement area 16of the first cushioning element 10 may include a plurality of cells 17that are defined by side walls 18 and that extend between a top surface16 t and a bottom surface 16 b of the peripheral engagement area 16. Atop end 17 t of each cell 17 may be open.

FIGS. 1 and 2 depict an embodiment of first cushioning element 10 inwhich the peripheral engagement area 16 is shorter or thinner than thecentral cushioning area 12.

The peripheral engagement area 16 of that embodiment is stepped, orrecessed, relative to the outer periphery 15 of the central cushioningarea 12. More specifically, the top surface 16 t of the peripheralengagement area 16 is at a different elevation than the top surface 12 tof the central cushioning area 12 and the bottom surface 16 b of theperipheral engagement area 16 is stepped up relative to the bottomsurface 12 b of the central cushioning area 12. Such a configurationresults in a peripheral engagement area 16 with outer edges that areshorter than a thickness of an outer periphery 15 of the centralcushioning area 12, enabling the second cushioning element 20 to lockonto the first cushioning element 10 without being thicker than thefirst cushioning element 10. Alternatively, the top surface 16 t of theperipheral engagement area 16 may be stepped down relative to the topsurface 12 t of the central cushioning area 12 while the bottom surfaces16 b and 12 b of the peripheral engagement area 16 and the centralcushioning area 12, respectively, are coplanar, or the bottom surface 16b of the peripheral engagement area 16 may be stepped up relative to thebottom surface 12 b of the central cushioning area 12 while the topsurfaces 16 t and 12 t of the peripheral engagement area 16 and thecentral cushioning area 12, respectively, are coplanar.

With continued reference to FIG. 1, in addition to the first cushioningelement 10 and the second cushioning element 20, the composite cushion 1includes a relief layer 30. The relief layer 30 is positioned on atleast a portion of the top surface 12 t of the central cushioning area12 of the first cushioning element 10. The relief layer 30 may bepositioned on the top surface 12 t of the central cushioning area 12without being secured to the top surface 12 t. Alternatively, the relieflayer 30 (e.g., one or more peripheral portions thereof, one or morecentral portions thereof, etc.) may be secured to the top surface 12 tof the central cushioning area 12 while a remainder of the relief layer30 (e.g., a majority of the portions of the relief layer 30 that contactthe top surface 12 t, etc.) may remain unsecured to the top surface 12t.

Peripheral portions 26 of the second cushioning element 20 at leastpartially surround the first cushioning element 10. In addition, theperipheral portions 26 of the second cushioning element 20 engage theperipheral engagement area 16 of the first cushioning element 10. Morespecifically, a material of the peripheral portions 26 of the secondcushioning element 20 extends through cells 17 in the peripheralengagement area 16 of the first cushioning element 10 to interlock theperipheral portion 26 of the second cushioning element 20 to theperipheral engagement area 16 of the first cushioning element 10.

A central portion 22 of the second cushioning element 20 covers therelief layer 30 on the top surface 12 t of the central cushioning area12 of the first cushioning element 10. Such an arrangement may enablecentral superimposed portions of the first cushioning element 10 and thesecond cushioning element 20 to function somewhat independently from oneanother and without significant interference from one another. As anexample, while the second cushioning element 20 located over the centralcushioning area 12 of the first cushioning element 10 providessubstantially constant cushioning and resistance without interferingwith the ability of the central cushioning area 12 of the firstcushioning element 10 to collapse under focused forces, while providingsupport to distributed forces.

FIGS. 3 and 4 illustrate an embodiment of a composite cushion 1′ thatincludes a first cushioning element 10 and a second cushioning element20′ with substantially the same thickness, or height. Thus, neither thetop surface 12 t nor the bottom surface 12 b of the central cushioningarea 12 of the first cushioning element 10 is covered any portion of thesecond cushioning element 20′; both of these major surfaces remainexposed. The second cushioning element 20′ extends around an entireouter periphery 15 of the central cushioning area 12 of the firstcushioning element 10, which may define a structure such as that shownin FIG. 3 or a laterally thinner “racetrack” structure around the firstcushioning element 10.

Turning now to FIGS. 5 and 6, another embodiment of first cushioningelement 10′ is illustrated. The first cushioning element 10′ includes acentral cushioning area 12′ and a peripheral engagement area 16′. Insome embodiments, the central cushioning area 12′ may include the samefeatures as the central cushioning area 12 of the embodiment of firstcushioning element 10 depicted by FIGS. 1 and 2.

The peripheral engagement area 16′ is located adjacent to at least aportion of an outer periphery 15′ of the central cushioning area 12′.Rather than have a stepped, or recessed, configuration like theperipheral engagement area 16 of the embodiment of first cushioningelement 10 depicted by FIGS. 1 and 2, the peripheral engagement area 16′of the first cushioning element 10′ illustrated by FIGS. 5 and 6 mayinclude top and bottom surfaces 16 t′ and 16 b′, respectively, that aretapered in such a way that outer edges 19′ of the peripheral engagementarea 16′ are shorter than a thickness of the central cushioning area 12′at an outer periphery 15′ thereof.

FIG. 7 provides a cross-sectional representation of another embodimentof first cushioning element 10″and of a composite cushion 1″ of whichthe first cushioning element 10″ is a part. The embodiment of firstcushioning element shown in FIG. 7 includes a peripheral engagement area16″ with one or more flanges 18″ that protrude from an outer periphery15″ of central cushioning area 12″of the first cushioning element 10″.Each flange 18″ defines recesses, including a top recess 18 t″ thatfaces upwardly and a bottom recess 18 b″ that faces downwardly. The toprecess 18 t″ and the bottom recess 18 b″may receive the material of asecond cushioning element 20″, as shown, thus enabling the secondcushioning element 20″ to engage, or lock onto, the first cushioningelement 10″. In some embodiments, the peripheral engagement area 16″ ofthe cushioning element 10″ may comprise a single flange 18″ that extendsalong a portion of the outer periphery 15″ of the central cushioningarea 12″of the first cushioning element 10″ that is to receive a secondcushioning element 12″ (e.g., along a portion of the outer periphery15″, around an entirety of the outer periphery 15″, etc.). In otherembodiments, the peripheral engagement area 16″ may comprise a pluralityof discrete flanges 18″ positioned along at least a portion of the outerperiphery 15″. Discrete flanges 18″may be short and/or elongated. Insome embodiments, discrete flanges 18″ may extend around corners of theouter periphery 15″ of the central cushioning area 12″ of the firstcushioning element 10″

FIG. 8 depicts, in cross-section, another embodiment of compositecushion 1′″ in which the peripheral engagement area 16′″ has a samethickness as the central cushioning area 12′″. A thickness of the secondcushioning element 20′″ exceeds a thickness of the first cushioningelement 10′″, with the top surface 21 t′″ of the second cushioningelement 20′″ being located at a higher elevation than the top surface 11t′″ of the first cushioning element 10′″ and the bottom surface and 21b′″ of the second cushioning element 20′″ being located at a lowerelevation than the bottom surface 11 b′″ of the first cushioning element10′″.

In addition, the composite cushion 1′″ shown in FIG. 8 includes a thirdcushioning element 40, which is positioned on at least the firstcushioning element 10′″ and, optionally, on the second cushioningelement 20′″.

In the embodiments of first cushioning elements 10, 10′, 10″, and 10′″depicted by FIGS. 1-8, their central cushioning areas 12, 12′, 12″, and12′″ include open-ended cells (e.g., cells 13 shown in FIGS. 1 and 2).As an alternative, as shown in FIGS. 9 and 10, the central cushioningarea 112 of a first cushioning element 110 may include a top surface 112t that comprises a membrane that extends at least partially over atleast some cells 113. In the depicted embodiment, the membrane thatdefines the top surface 112 t of the central cushioning area 112 maycompletely cover the top ends 113 t of some cells 113 and partiallycover the top ends 113 t′ of other cells 113′. Thus, openings 112 o mayextend through some locations of the membrane that defines the topsurface 112 t.

As FIG. 10 shows, during formation of a second cushioning element 120with a central portion 122 that at least partially overlaps, or that isat least partially superimposed over, the central cushioning area 112 ofthe first cushioning element 110, material from which the secondcushioning element 120 is formed may be introduced into through openings112 o in the top surface 112 t and into their respective cells 113′.That material may be subsequently removed from the cells 113′.

Any embodiment of first cushioning element 10, 10′, 10″, 10′″, 110(FIGS. 1-10) may be formed by any of a variety of suitable processes,including, but not limited to, the use of molds (e.g., by injecting thefirst cushioning material (e.g., a gel, etc.) into a mold, etc.). Once afirst cushioning element 10, 10′, 10″, 10′″, 110 has been formed, it maybe placed into another mold. In some embodiments, a relief layer 30(FIG. 1) may be applied to at least a portion of the top surface 12 t(FIG. 1) of the central cushioning area 12, 12′, 12″, 12′″ of the firstcushioning element 10, 10′, 10″, 10′″ (FIGS. 1-8). The relief layer 30may be placed on the central cushioning area 12, 12′, 12″, 12′″ of thefirst cushioning element 10, 10′, 10″, 10′″ without adhering to orotherwise being secured to the top surface 12 t.

With the first cushioning element 10, 10′, 10″, 10′″, 110 (FIGS. 1-10)and any relief layer 30 (FIG. 1) in the mold, a second cushioningmaterial (e.g., a rise in place foam, etc.) may be introduced into(e.g., injected, etc.) the mold to form the second cushioning element20, 20′, 20″, 20′″, 120 (FIGS. 3, 4, 7, 8 and 10), including anyengagement features thereof, laterally adjacent to at least a portion ofthe first cushioning element 10, 10′, 10″, 10′″, 110. In embodimentssuch as that depicted by FIGS. 9 and 10 where the second cushioningmaterial is applied directly to the top surface 112 t of the centralcushioning area 112 of the first cushioning element 110 and the secondcushioning material enters into cells 113′ of the central cushioningarea 112, the second cushioning material may be removed from those cells113′ after the second cushioning element 120 has been formed.

Although the preceding disclosure provides many specifics, these shouldnot be construed as limiting the scope of any of the ensuing claims.Other embodiments may be devised which do not depart from the scopes ofthe claims. Features from different embodiments may be employed incombination. The scope of each claim is, therefore, indicated andlimited only by its plain language and the full scope of available legalequivalents to its elements.

What is claimed:
 1. A composite cushioning element, comprising: a firstcushioning element comprising a first cushioning structure, the firstcushioning element including: a central cushioning area having a centralcushion thickness, a first cushioning material of the central cushioningarea forming the first cushioning structure, including walls defining anouter periphery of the central cushioning area and columnar cushioningcells within the outer periphery, the first cushioning material enablingthe walls and the columnar cells to buckle, a first surface of thecentral cushioning area defined by first ends of the walls andcoincident with first ends of the columnar cushioning cells, a secondsurface of the central cushioning area opposite from the first surface,defined by second ends of the walls opposite from the first ends of thewalls, and coincident with second ends of the columnar cushioning cellsopposite from the first ends of the columnar cushioning cells; aperipheral engagement area located outside of and adjacent to at least aportion of the outer periphery of the central cushioning area, theperipheral engagement area having an engagement thickness, theperipheral engagement area defined by the first cushioning material, afirst surface of the peripheral engagement area corresponding to thefirst surface of the central cushioning area, a second surface of theperipheral engagement area opposite from the first surface andcorresponding to the second surface of the central cushioning area; asecond cushioning element comprising a second cushioning structureadjacent to at least a portion of the outer periphery of the centralcushioning area of the first cushioning element, a second cushioningmaterial including features formed complementarily to the peripheralengagement area to mechanically secure the second cushioning element tothe first cushioning element.
 2. The composite cushioning element ofclaim 1, wherein the second cushioning element laterally surrounds anentirety of the outer periphery of the central cushioning area of thefirst cushioning element.
 3. The composite cushioning element of claim1, wherein the second cushioning structure comprises a foamed cushioningstructure.
 4. The composite cushioning element of claim 1, wherein thefirst cushioning material of the peripheral engagement area definesengagement cells adjacent to the outer periphery of the centralcushioning area, the first surface of the peripheral engagement areabeing coincident with first ends of the engagement cells, the secondsurface of the peripheral engagement area being coincident with secondends of the engagement cells, the second ends of the engagement cellsopposite from the first ends of the engagement cells.
 5. The compositecushioning element of claim 4, wherein the second cushioning materialextends into and through the engagement cells of the peripheralengagement area of the first cushioning element to mechanically securethe second cushioning element to the first cushioning element.
 6. Thecomposite cushioning element of claim 4, wherein the engagementthickness of the peripheral engagement area of the first cushioningelement is the same as the central cushion thickness of the centralcushioning area of the first cushioning element.
 7. The compositecushioning element of claim 4, wherein the second cushioning elementcovers the first surface of the peripheral engagement area of the firstcushioning element.
 8. The composite cushioning element of claim 7,wherein the second cushioning element covers the second surface of theperipheral engagement area of the first cushioning element.
 9. Thecomposite cushioning element of claim 7, wherein the second cushioningelement covers at least a portion of the first surface of the centralcushioning area of the first cushioning element.
 10. The compositecushioning element of claim 9, further comprising: a relief layerbetween superimposed portions of the second cushioning element and thecentral cushioning area of the first cushioning element, the relieflayer not being adhered to or directly secured to a majority of thefirst surface of the central cushioning area of the first cushioningelement.
 11. The composite cushioning element of claim 4, wherein atleast one of the first surface of the peripheral engagement area of thefirst cushioning element and the second surface of the peripheralengagement area of the first cushioning element is oriented at an anglerelative to a corresponding surface of the central cushioning area ofthe first cushioning element to impart the peripheral engagement areawith a narrowing taper from the outer periphery of the centralcushioning area to an outer peripheral edge of the peripheral engagementarea.
 12. The composite cushioning element of claim 4, wherein at leastone of the first surface of the peripheral engagement area of the firstcushioning element and the second surface of the peripheral engagementarea of the first cushioning element is stepped to impart the peripheralengagement area with an outer peripheral edge that is shorter than athickness of the central cushioning area at the outer periphery of thecentral cushioning area.
 13. The composite cushioning element of claim1, further comprising: a third cushioning element positioned over thefirst cushioning element and the second cushioning element.
 14. A methodfor fabricating a cushion, comprising: forming a first cushioningelement from a first cushioning material, the first cushioning elementcomprising walls defining columnar cushioning cells in a centralcushioning area of the first cushioning element and engagement featuresin a peripheral engagement area adjacent to an outer periphery of thecentral cushioning area, major surfaces of the central cushioning areaof the first cushioning element being defined by exposed edges of thewalls and coincident with ends of the columnar cushioning cells; andforming a second cushioning element, including: forming a secondcushioning material to a shape complementary to shapes of the engagementfeatures in the peripheral engagement area of the first cushioningelement to define engagement elements of the second cushioning element;and defining a remainder of the second cushioning element from thesecond cushioning material.
 15. The method of claim 14, furthercomprising: positioning the first cushioning element into a mold. 16.The method of claim 15, wherein forming the second cushioning elementcomprises introducing the second cushioning material into the mold afterpositioning the first cushioning element into the mold.
 17. The methodof claim 14, wherein forming the second cushioning element includesapplying the second cushioning material over at least a portion of thecentral cushioning area of the first cushioning element.
 18. The methodof claim 17, further comprising: positioning a relief layer over atleast a portion of the central cushioning area of the first cushioningelement before forming the second cushioning element without adheringthe relief layer to a majority of an upper surface of the centralcushioning area.
 19. The method of claim 14, wherein forming the firstcushioning element comprises forming the first cushioning element withthe engagement features of the peripheral engagement area comprisingengagement cells.
 20. The method of claim 19, wherein forming the secondmaterial to the shape complementary to shapes of the engagement featuresin the peripheral area of the first cushioning element comprisesintroducing the second cushioning material into and through theengagement cells of the peripheral engagement area of the firstcushioning element.